Surgical instrument with switch activation control

ABSTRACT

A surgical instrument includes a housing and an elongated shaft operably coupled to an actuating mechanism moveable between an actuated position and an unactuated position. An end effector includes a pair of opposing first and second jaw members and is adapted to connect to a source of electrosurgical energy. A switch is moveable between an activated position to initiate delivery of electrosurgical energy to the end effector and a deactivated position to terminate delivery of electrosurgical energy to the end effector. A switch activation member is configured to move the switch between an activated position and a deactivated position. A switch control member is configured to maintain the switch in the activated position during at least partial movement of the actuating mechanism from the actuated position to the unactuated position.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/226,650, filed on Aug. 2, 2016, now U.S. Pat. No. 10,335,228, whichis a continuation of U.S. patent application Ser. No. 14/105,374, filedon Dec. 13, 2013, now U.S. Pat. No. 9,456,863, which claims the benefitof the filing date of provisional U.S. Patent Application No.61/776,185, filed on Mar. 11, 2013, the entire contents of each of whichare incorporated herein by reference.

INTRODUCTION

The present disclosure relates generally to the field of surgicalinstruments. In particular, the present disclosure relates to anendoscopic electrosurgical forceps that includes a system and method forcontrolling the activation and deactivation of treatment energy.

BACKGROUND

Instruments such as electrosurgical forceps are commonly used in openand endoscopic surgical procedures to coagulate, cauterize and sealtissue. Such forceps typically include a pair of jaws that can becontrolled by a surgeon to grasp targeted tissue, such as, e.g., a bloodvessel. The jaws may be approximated to apply a mechanical clampingforce to the tissue, and are associated with at least one electrode topermit the delivery of electrosurgical energy to the tissue. Thecombination of the mechanical clamping force and the electrosurgicalenergy has been demonstrated to join adjacent layers of tissue capturedbetween the jaws. When the adjacent layers of tissue include the wallsof a blood vessel, sealing the tissue may result in hemostasis, whichmay facilitate the transection of the sealed tissue. A detaileddiscussion of the use of an electrosurgical forceps may be found in U.S.Pat. No. 7,255,697 to Dycus et al.

A bipolar electrosurgical forceps typically includes opposed electrodesdisposed on clamping faces of the jaws. The electrodes are charged toopposite electrical potentials such that an electrosurgical current maybe selectively transferred through tissue grasped between theelectrodes. To effect a proper seal, particularly in relatively largevessels, two predominant mechanical parameters must be accuratelycontrolled; the pressure applied to the vessel, and the gap distanceestablished between the electrodes.

Both the pressure and gap distance influence the effectiveness of theresultant tissue seal. If an adequate gap distance is not maintained,there is a possibility that the opposed electrodes will contact oneanother, which may cause a short circuit and prevent energy from beingtransferred through the tissue. Also, if too low a force is applied thetissue may have a tendency to move before an adequate seal can begenerated. The thickness of a typical effective tissue seal is optimallybetween about 0.001 and about 0.006 inches. Below this range, the sealmay shred or tear and above this range the vessel walls may not beeffectively joined. Closure pressures for sealing large tissuestructures preferably fall within the range of about 3 kg/cm² to about16 kg/cm².

SUMMARY

The present disclosure relates generally to the field of surgicalinstruments. In particular, the present disclosure relates to anendoscopic electrosurgical forceps that includes a system and method forcontrolling the activation and deactivation of treatment energy.

As is traditional, the term “distal” refers herein to an end of theapparatus that is farther from an operator, and the term “proximal”refers herein to the end of the electrosurgical forceps that is closerto the operator.

According to one aspect of the present disclosure, a surgical instrumentis provided. The surgical instrument includes a housing and an elongatedshaft. The elongated shaft has a distal portion extending from thehousing and a proximal portion coupled to the housing. A longitudinalaxis is defined through the elongated shaft. An actuating mechanism isoperably coupled to the elongated shaft and is moveable relative to thehousing between an actuated position and an unactuated position toselectively move the elongated shaft along the longitudinal axis. An endeffector includes a pair of opposing first and second jaw membersmovable relative to each other from a first position wherein the jawmembers are disposed in spaced relation relative to one another to asecond position wherein the jaw members cooperate to grasp tissue. Theend effector is adapted to connect to a source of electrosurgical energyfor conducting electrosurgical energy through tissue grasped between thejaw members to effect a tissue seal. A switch is supported by thehousing and moveable between an activated position to initiate deliveryof electrosurgical energy from the electrosurgical energy source to theend effector and a deactivated position to terminate delivery ofelectrosurgical energy from the electrosurgical energy source to the endeffector. A switch activation member is disposed on the actuatingmechanism and is configured to move the switch to the activated positionupon movement of the actuating mechanism to the actuated position and tothe deactivated position upon movement of the actuating mechanism to theunactuated position. A switch control member is configured to maintainthe switch in the activated position during at least partial movement ofthe actuating mechanism from the actuated position to the unactuatedposition.

Additionally or alternatively, the surgical instrument may also includea knife blade supported in the elongated shaft and moveable in alongitudinal direction through a knife channel defined along a length ofat least one of the jaw members to cut tissue disposed between the jawmembers.

Additionally or alternatively, the switch may be operably coupled to adepressible button extending from the housing and configured to beselectively engaged by the switch activation member upon movement of theactuating mechanism to the actuated position.

Additionally or alternatively, the switch control member may include abiasing member disposed between the depressible button and the switch.The biasing member may be configured to maintain a force on the switchto maintain the switch in the activated position during at least partialmovement of the actuating mechanism from the actuated position to theunactuated position.

Additionally or alternatively, the switch control member may include abiasing member extending from the actuating mechanism and having abutton activation post configured to engage the depressible button. Thebiasing member may be configured to maintain a force on the switch tomaintain the switch in the activated position during at least partialmovement of the actuating mechanism from the actuated position to theunactuated position.

Additionally or alternatively, the switch control member may include abiasing member disposed between the depressible button and the switch.The depressible button may have a switch activation post extendingtherefrom at least partially through the biasing member. The biasingmember may be configured to maintain a force on the switch to maintainthe switch in the activated position during at least partial movement ofthe actuating mechanism from the actuated position to the unactuatedposition.

Additionally or alternatively, the switch control member may include abiasing member extending from the actuating mechanism configured tomaintain a force on the switch to maintain the switch in the activatedposition during at least partial movement of the actuating mechanismfrom the actuated position to the unactuated position.

Additionally or alternatively, the second jaw member may be mechanicallycoupled to a distal end of the elongated shaft and the first jaw membermay be configured to move relative to the second jaw member.

Additionally or alternatively, the switch control member may include aleaf spring.

Additionally or alternatively, the switch control member may include acoiled spring.

Additionally or alternatively, the surgical instrument may also includea stationary actuation member axially disposed within the elongatedshaft. The stationary actuation member may include a cam pinmechanically coupled to the distal portion of the elongated shaft. Oneor both of the first and second jaw members may include a camming slotconfigured to engage the cam pin to move the at least one movable jawmember about a pivot between the first position and the second positionupon movement of the elongated shaft along the longitudinal axis.

Additionally or alternatively, an electrical insulator may be coupled toone or both of the jaw members.

Additionally or alternatively, the surgical instrument may also includean electrically conductive tissue sealing surface extending along alength of at least one jaw member and adapted to connect to the sourceof electrosurgical energy.

According to another aspect of the present disclosure, a surgicalinstrument is provided. The surgical instrument includes a housing andan elongated shaft. The elongated shaft has a distal portion extendingfrom the housing and a proximal portion coupled to the housing. Alongitudinal axis is defined through the elongated shaft. An actuatingmechanism is operably coupled to the elongated shaft and is moveablerelative to the housing between an actuated position and an unactuatedposition to selectively move the elongated shaft along the longitudinalaxis. An end effector includes a pair of opposing first and second jawmembers movable relative to each other from a first position wherein thejaw members are disposed in spaced relation relative to one another to asecond position wherein the jaw members cooperate to grasp tissue. Theend effector is adapted to connect to a source of electrosurgical energyfor conducting electrosurgical energy through tissue grasped between thejaw members to effect a tissue seal. A switch is supported by thehousing and moveable between an activated position to initiate deliveryof electrosurgical energy from the electrosurgical energy source to theend effector and a deactivated position to terminate delivery ofelectrosurgical energy from the electrosurgical energy source to the endeffector. A switch activation member is disposed on the actuatingmechanism and is configured to move the switch to the activated positionupon movement of the actuating mechanism to the actuated position and tothe deactivated position upon movement of the actuating mechanism to theunactuated position. A switch control member is configured to maintainthe switch in the activated position during at least partial movement ofthe actuating mechanism from the actuated position to the unactuatedposition. A knife blade is supported in the elongated shaft and ismoveable in a longitudinal direction through a knife channel definedalong a length of at least one of the jaw members to cut tissue disposedbetween the jaw members.

Additionally or alternatively, the switch may be operably coupled to adepressible button extending from the housing and configured to beselectively engaged by the switch activation member upon movement of theactuating mechanism to the actuated position.

Additionally or alternatively, the switch control member may be disposedbetween the depressible button and the switch.

Additionally or alternatively, the switch control member may be disposedon the actuating mechanism.

According to another aspect of the present disclosure, a switchactuation control mechanism for an electrosurgical instrument having ahousing and an end effector adapted to connect to a source ofelectrosurgical energy for conducting electrosurgical energy throughtissue grasped by the end effector to effect a tissue seal is provided.The switch actuation control mechanism including a switch supported bythe housing. The switch is moveable between an activated position toinitiate delivery of electrosurgical energy from the electrosurgicalgenerator to the end effector and a deactivated position to terminatedelivery of electrosurgical energy from the electrosurgical generator tothe end effector. A switch activation member is moveable between anactuated position and an unactuated position to selectively move theswitch between the activated position and the deactivated position. Aswitch control member is configured to maintain the switch in theactivated position during at least partial movement of the switchactivation member from the actuated position to the unactuated position.

Additionally or alternatively, the switch control member may be disposedbetween the switch and the switch activation member.

Additionally or alternatively, the switch control member may include abiasing member configured to maintain a force on the switch to maintainthe switch in the activated position during at least partial movement ofthe switch activation member from the actuated position to theunactuated position.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the presentdisclosure and, together with the detailed description of theembodiments given below, serve to explain the principles of thedisclosure.

FIG. 1 is a perspective view of an electrosurgical forceps according toan embodiment of the present disclosure including a housing, anelongated shaft, and an end effector;

FIG. 2A is an enlarged, perspective view of the end effector of FIG. 1depicted with a pair of jaw members in an open configuration;

FIG. 2B is an enlarged, perspective view of the end effector of FIG. 1depicted with the pair of jaw members in a closed configuration;

FIG. 3A is a perspective view of the end effector and elongated shaft ofFIG. 1 with parts separated;

FIG. 3B is cross-sectional view taken along line 3B-3B of FIG. 3Ashowing a distal portion of the electrosurgical forceps of FIG. 1depicting a tube guide;

FIG. 4 is a proximally-facing, perspective view of a rotation knobdepicting a passageway for receiving the elongated shaft of FIG. 1;

FIG. 5 is a cross-sectional, perspective view of the end effector ofFIG. 1;

FIG. 6 is a partial, proximal-facing perspective view of a distalportion of a jaw actuation mechanism of the end effector of FIG. 1;

FIG. 7 is a partial, distal-facing perspective view of distal portion ofa knife actuation mechanism of the end effector of FIG. 1;

FIG. 8 is a top, perspective view of a lower jaw member of the endeffector of FIG. 1;

FIG. 9 is a top, cross-sectional, perspective view of the lower jawmember of FIG. 8;

FIG. 10 is a perspective view of a proximal portion of the instrument ofFIG. 1 with a portion of the housing removed revealing internalcomponents;

FIG. 11 is a partial, side view of a proximal portion of the instrumentof FIG. 1;

FIG. 12A is an enlarged, perspective view of a proximal portion of theknife actuation mechanism of the end effector of FIG. 1;

FIG. 12B is an enlarged, cross-sectional, side view of a knife collar ofthe knife actuation mechanism of the end effector of FIG. 1;

FIG. 13A is an internal, side view of the proximal portion of theinstrument of FIG. 10 depicting a movable handle in a separated positionwith respect to a stationary handle, which corresponds to the openconfiguration of the end effector depicted in FIG. 2A, and a knifetrigger in a separated configuration with respect to the stationaryhandle, which corresponds to an un-actuated or proximal configuration ofa knife with respect to the jaw members;

FIG. 13B is an internal, side view of the proximal portion of theinstrument of FIG. 10 depicting the movable handle in an intermediateposition with respect to the stationary handle, which corresponds to afirst closed configuration of the end effector wherein the jaw membersencounter one another;

FIG. 13C is an internal, side view of the proximal portion of theinstrument of FIG. 10 depicting the movable handle in an approximatedconfiguration with respect to the stationary handle, which correspondsto a second closed configuration of the end effector wherein the jawmembers apply an appropriate pressure to generate a tissue seal; and

FIG. 13D is an internal, side view of the proximal portion of theinstrument of FIG. 10 depicting the knife trigger in an actuatedconfiguration, which corresponds to an actuated or distal position ofthe knife with respect to the jaw members.

DETAILED DESCRIPTION

Referring initially to FIG. 1, an embodiment of an electrosurgicalforceps 100 generally includes a housing 112 that supports variousactuators thereon for remotely controlling an end effector 114 throughan elongated shaft 116. Although this configuration is typicallyassociated with instruments for use in laparoscopic or endoscopicsurgical procedures, various aspects of the present disclosure may bepracticed with traditional open instruments and in connection withcertain endoluminal procedures.

The housing 112 is constructed of a left housing half 112 a and a righthousing half 112 b. The left and right designation of the housing halves112 a, 112 b refer to the respective directions as perceived by anoperator using the forceps 100. The housing halves 112 a, 112 b areconstructed of sturdy plastic, and are joined to one another byadhesives, ultrasonic welding or other suitable assembly methods.

To mechanically control the end effector 114, the housing 112 supports astationary handle 120, a movable handle 122, a trigger 126 and arotation knob 128. The movable handle 122 is operable to move the endeffector 114 between an open configuration (FIG. 2A) wherein a pair ofopposed jaw members 130, 132 are disposed in spaced relation relative toone another, and a closed or clamping configuration (FIG. 2B) whereinthe jaw members 130, 132 are closer together. Approximation of themovable handle 122 with the stationary handle 120 serves to move the endeffector 114 to the closed configuration and separation of the movablehandle 122 from the stationary handle 120 serves to move the endeffector 114 to the open configuration. The trigger 126 is operable toextend and retract a knife blade 156 (see FIGS. 2A and 2B) through theend effector 114 when the end effector 114 is in the closedconfiguration. The rotation knob 128 serves to rotate the elongatedshaft 116 and the end effector 114 about a longitudinal axis A-Aextending through the forceps.

To electrically control the end effector 114, the stationary handle 120supports a depressible button 137 thereon, which is operable by the userto initiate and terminate the delivery of electrosurgical energy to theend effector 114. More specifically, and as illustrated in FIGS.13A-13D, the depressible button 137 is mechanically coupled to a switch136 disposed within the stationary handle 120. In some embodiments, thebutton 137 is engageable by a button activation post 138 extending froma proximal side of the moveable handle 122 upon proximal movement of themoveable handle 122. The switch 136 is in electrical communication witha source of electrosurgical energy such as electrosurgical generator 141or a battery (not shown) supported within the housing 112. The generator141 may include devices such as the LIGASURE® Vessel Sealing Generatorand the Force Triad® Generator sold by Covidien Energy-based Devices ofBoulder, Colo. A cable 143 extends between the housing 112 and thegenerator 141 and includes a connector (not shown) thereon such that theforceps 100 may be selectively coupled and decoupled electrically fromthe generator 141.

As further detailed hereinbelow, a user squeezes moveable handle 122 toapproximate the moveable handle 122 with the stationary handle 120 andactivate the switch 136 to initiate the delivery of electrosurgicalenergy to the end effector 114 and effect a tissue seal. Upon completionof a tissue seal, the user operates the trigger 126 to advance the knifeblade 156 through the end effector 114 when the end effector 114 is inthe closed configuration. As the user reaches for the trigger 126 withthe same hand that is squeezing the moveable handle 122 to keep the endeffector 114 in the closed configuration, the moveable handle 122 mayinadvertently move distally away from the stationary handle 120. Thisdistal movement of the moveable handle 122 may cause the buttonactivation post 138 to disengage the button 137 and, in turn, the button137 disengages and deactivates the switch 136 to terminate delivery ofelectrosurgical energy to the end effector 114. When the user moves thetrigger 126 proximally to advance the knife blade 156 through the endeffector 114, the user re-squeezes the moveable handle 122 such thatbutton activation post 138 reengages and depresses the button 137,thereby reactivating the switch 136. Reactivation of the switch 136reinitiates the delivery of electrosurgical energy to the end effector114 while the knife blade 156 is advanced through the end effector 114.

In some embodiments, the forceps 100 may include an enhanced switchcontrol feature configured to prevent the deactivation and reactivationof the switch 136 to terminate and reinitiate, respectively, thedelivery of electrosurgical energy to the end effector 114 duringoperation of the trigger 126. With reference to FIG. 10, one suchembodiment is depicted, wherein the button 137 includes a switchactivation post 137 a extending therefrom and a biasing member 136 a(e.g., a coiled spring) disposed about the switch activation post 137 abetween the switch 136 and the button 137. Switch activation post 137 ais positioned relative to the switch 136 such that when buttonactivation post 138 engages and depresses button 137 upon approximationof moveable handle 122 with stationary handle 120, switch activationpost 137 a engages and activates switch 136. Depression of button 137also causes biasing member 136 a to compress between the button 137 andthe switch 136 and to apply a spring force on switch 136. If themoveable handle 122 inadvertently moves distally away from thestationary handle 120 during operation of the trigger 126, the biasingmember 136 a, although now slightly decompressed, serves to mitigate theeffects of this distal movement of the moveable handle 122 bymaintaining a spring force on the switch 136. This spring forcemaintained on the switch 136 is sufficient to keep the switch 136activated during at least a portion of travel of the moveable handle 122in the distal direction, such that the switch 136 is not deactivated andreactivated during operation of the trigger 126. As the moveable handle122 moves farther away from the stationary handle 120 to move the endeffector 114 to the open configuration (FIG. 2A), the spring forcemaintained on the switch 136 by the biasing member 136 a relents and, asa result, the switch 136 is deactivated.

Referring now to FIGS. 2A-3, the end effector 114 may be moved from theopen configuration (FIG. 2A) wherein tissue (not shown) is receivedbetween the jaw members 130, 132, and the closed configuration (FIG.2B), wherein the tissue is clamped and treated. The upper and lower jawmembers 130, 132 are electrically coupled to cable 143, and thus to thegenerator 141 (e.g., via a respective wire extending through theelongated shaft 116) to provide an electrical pathway to a pair ofelectrically conductive, tissue-engaging sealing plates 148, 150disposed on the lower and upper jaw members 132, 130, respectively. Thesealing plate 148 of the lower jaw member 132 opposes the sealing plate150 of the upper jaw member 130, and, in some embodiments, the sealingplates 148 and 150 are electrically coupled to opposite terminals, e.g.,positive or active (+) and negative or return (−) terminals associatedwith the generator 141. Thus, bipolar energy may be provided through thesealing plates 148 and 150. Alternatively, the sealing plates 148 and150 and/or the end effector 114 may be configured for deliveringmonopolar energy to the tissue. In a monopolar configuration, one orboth sealing plates 148 and 150 deliver electrosurgical energy from anactive terminal, e.g. (+), while a return pad (not shown) is placedgenerally on a patient and provides a return path to the oppositeterminal, e.g. (−), of the generator 141. Each jaw member 130, 132includes a jaw insert 140 and an insulator 142 that serves toelectrically insulate the sealing plates 150, 148 from the jaw insert140 of jaw members 130, 132, respectively.

Referring to FIG. 3, the elongated shaft 116 includes variouslongitudinal components that operatively couple the end effector 114 tothe various actuators supported by the housing 112 (FIG. 1). An outershaft member 160 defines an exterior surface of the elongated shaft 116and supports movement of other components therethrough as describedbelow. The outer shaft member 160 is configured for longitudinal motionwith respect to an inner actuation member 180 axially received withinthe outer shaft member 160. The inner actuation member 180 may be a rod,shaft, stamped metal, or other suitable mechanical component. A proximalportion 166 of the outer shaft member 160 is configured for receiptwithin the housing 112 (FIG. 1), and includes features for operativelycoupling the outer shaft member 160 to the actuators supported thereon,e.g. the movable handle 122. A distal portion 186 of the inner actuationmember 180 includes a longitudinal recess 190 defined therein thatprovides clearance for the pivot pin 144 and thus, permits longitudinalreciprocation of the pivot pin 144 (via longitudinal reciprocation ofthe outer shaft member 160) independent of the inner actuation member180. Distally of the longitudinal recess 190, the cam pin 192 ismechanically coupled (e.g., via welding, friction-fit, laser welding,etc.) to the distal portion 186 of the inner actuation member 180. Aproximal portion 188 of the inner actuation member 180 includes a washer187 coupled thereto (FIG. 10). The washer 187 is supported within thehousing 112 and serves to prohibit longitudinal motion of the inneractuation member 180 parallel to the longitudinal axis A-A.

The jaw members 130, 132 may be pivoted about the pivot pin 144 to movethe end effector 114 to the closed configuration of FIG. 2B wherein thesealing plates 148, 150 provide a pressure to tissue graspedtherebetween. In some embodiments, to provide an effective seal, apressure within a range between about 3 kg/cm² to about 16 kg/cm² and,desirably, within a working range of 7 kg/cm² to 13 kg/cm² is applied tothe tissue. Also, in the closed configuration, a separation or gapdistance “G” may be maintained between the sealing plates 148, 150 by anarray of stop members 154 (FIG. 2A) disposed on or adjacent the sealingplates 148, 150. The stop members 154 contact opposing surfaces on theopposing jaw member 130, 132 and prohibit further approximation of thesealing plates 148, 150. In some embodiments, to provide an effectivetissue seal, an appropriate gap distance of about 0.001 inches to about0.010 inches and, desirably, between about 0.002 and about 0.005 inchesmay be provided. In some embodiments, the stop members 154 areconstructed of an electrically non-conductive plastic or other materialmolded onto the jaw members 130, 132, e.g., by a process such asovermolding or injection molding. In other embodiments, the stop members154 are constructed of a heat-resistant ceramic deposited onto the jawmembers 130, 132.

Electrosurgical energy may be delivered to the tissue through theelectrically conductive seal plates 148, 150 to effect a tissue seal.Once a tissue seal is established, a knife blade 156 having a sharpdistal cutting edge 157 may be advanced through a knife channel 158defined in one or both jaw members 130, 132 to transect the sealedtissue. Knife blade 156 is depicted in FIG. 2A as extending from theelongated shaft 116 when the end effector 114 is in an openconfiguration. In some embodiments, a knife lockout is provided toprevent extension of the knife blade 156 into the knife channel 158 whenthe end effector 114 is in the open configuration.

The proximal portion 166 of the outer shaft member 160 includes variousfeatures that serve to couple the outer shaft member 160 to variouselements of the housing 112. More specifically, the proximal portion 166of the outer shaft member 160 includes, in order from distal toproximal, a longitudinal slot 169 extending distally from a proximal endthereof to couple the outer shaft member 160 to the rotation knob 128, alongitudinal knife slot 168 defined therethrough, a pair of opposingdistal locking slots 161 a, 161 b, and a pair of opposing proximallocking slots 171 a, 171 b. The connection established between the outershaft member 160 and the rotation knob 128 is described below withreference to FIG. 4.

The pivot pin 144 extends through a proximal portion of each of the jawmembers 130, 132 to pivotally support the jaw members 130, 132 at thedistal end of the outer shaft member 160. With reference to FIG. 8, aproximal portion of each of the jaw members 130, 132 includes twolaterally spaced parallel flanges or “flags” 130 a, 130 b and 132 a, 132b respectively, extending proximally from a distal portion of the jawmembers 130 and 132. A lateral cam slot 130 c and a lateral pivot bore130 d extend through each of the flags 130 a, 130 b of the upper jawmember 130. Similarly, a lateral cam slot 132 c and a lateral pivot bore132 d extend through each of the flags 132 a, 132 b of the lower jawmember 132. The pivot bores 130 d, 132 d receive the pivot pin 144 in aslip-fit relation that permits the jaw members 130, 132 to pivot aboutthe pivot pin 144 to move the end effector 114 between the open andclosed configurations (FIGS. 2A and 2B, respectively).

A knife rod 102 is coupled (e.g., via welding) at a distal-most end tothe sharpened knife blade 156 and includes an angled proximal end 108that provides a mechanism for operatively coupling the knife rod 102 tothe trigger 126. The connection between the knife rod 102 and thetrigger 126 is described in detail below with reference to FIGS. 10, 11,12A, and 12B. The sharp edge 157 of the knife blade 156 may be appliedto the distal end of the knife blade 156 subsequent to the stampingprocess that forms the profile. For example, various manufacturingtechniques may be employed such as grinding, coining, electrochemicaletching, electropolishing, or other suitable manufacturing processes,for forming sharpened edges.

Referring to FIGS. 3A and 3B, a tube guide 109 is disposed within theouter shaft member 160 and includes a guide lumen 107 axially disposedtherethrough and a longitudinal guide recess 105 formed therein. Theinner actuation member 180 is received within the guide lumen 107, whichserves to orient and align the inner actuation member 180 within theouter shaft member 160. The knife rod 102 is received within thelongitudinal recess 105, which serves to guide longitudinal motion ofthe knife rod 102 within the outer shaft member 160. In this way, theinner actuation member 180 and the knife rod 102 are aligned within theouter shaft member 160 by the tube guide 109 such that the knife rod 102is free to move longitudinally relative to the inner actuation member180.

Referring now to FIG. 4, the rotation knob 128 includes a passageway 129defined therethrough for receiving the outer shaft member 160. Thepassageway 129 has a generally circular profile corresponding to thecircular profile of the outer shaft member 160. The passageway 129includes a longitudinal keying member 124 that is configured to alignwith and be seated within longitudinal slot 169 (FIG. 3A) of the outershaft member 160. The keying member 124 projects laterally inward alongthe length of passageway 129 such that the insertion of the proximal endof the outer shaft member 160 into the passageway 129 of the rotationknob 128 operatively couples the outer shaft member 160 to the rotationknob 128. Rotational motion imparted to the rotation knob 128 may thusimpart rotational motion to each of the components of the elongatedshaft 116, and to the end effector 114, which is coupled thereto. Asshown in FIG. 12, the rotation knob 128 is seated within an interiorcompartment 134 of the housing 112 and, as shown in FIG. 1, extendslaterally outward from opposing sides of the housing 112 (only shownextending laterally outward from housing half 112 b).

Referring now to FIG. 5, the end effector 114 is coupled to the distalend of the inner actuation member 180 by the cam pin 192. The cam pin192 represents a longitudinally stationary reference for thelongitudinal movements of the outer shaft member 160, the pivot pin 144,and the knife rod 102. The cam pin 192 extends through the flags 132 a,132 b of the lower jaw member 132 and the flags 130 a and 130 b of theupper jaw member 130.

Referring now to FIG. 6, the end effector 114 is shown in the openconfiguration. Since the inner actuation member 180 is coupled to thecam pin 192, when the outer shaft member 160 is in the distal position(unactuated) and the inner actuation member 180 is in the proximalposition relative to the outer shaft member 160, the cam pin 192 islocated in a proximal position in cam slots 130 c and 132 c definedthrough the flags 130 a, 130 b, 132 a, 132 b of the jaw members 130,132, respectively.

The outer shaft member 160 may be drawn proximally relative to the inneractuation member 180 and the cam pin 192 to move the end effector 114 tothe closed configuration (see FIG. 2B). Since the longitudinal positionof the cam pin 192 is fixed, and since the cam slots 130 c, 132 c areobliquely arranged with respect to the longitudinal axis A-A, proximalretraction of the outer shaft member 160 induces distal translation ofthe cam pin 192 through the cam slots 130 c, 132 c and jaw member 130 topivot toward jaw member 132 about the pivot pin 144. Conversely, whenthe end effector 114 is in the closed configuration, longitudinaltranslation of the outer shaft member 160 in a distal direction inducesproximal translation of the cam pin 192 through the cam slots 130 c, 132c and jaw member 130 to pivot away from jaw member 132 toward the openconfiguration.

Referring now to FIG. 7, the pins 144, 192 do not interfere with thereciprocal motion of the knife blade 156. A proximal portion of theinsulator 142 forms a blade guide 142 a (also see FIGS. 8 and 9) thatserves to align the knife blade 156 such that the knife blade 156readily enters the knife channel 158 defined in the jaw members 130, 132(jaw member 130 removed from view in FIG. 7 for clarity).

Referring now to FIGS. 8 and 9, the lower jaw member 132 is constructedof three major components. These components include the jaw insert 140,the insulator 142, and the sealing plate 148. The flags 132 a, 132 b ofthe jaw member 132 define a proximal portion of the jaw insert 140 and agenerally u-shaped profile of the jaw insert 140 extends distally tosupport the tissue engaging portion of the jaw member 132. Upper jawmember 130 includes the same three major components as lower jaw member132, including sealing plate 150, and is constructed in the same manneras lower jaw member 132.

The insulator 142 may be constructed of an electrically insulativeplastic such as a polyphthalamide (PPA) (e.g., Amodel®), polycarbonate(PC), acrylonitrile butadiene styrene (ABS), a blend of PC and ABS,nylon, ceramic, etc. The electrically insulative plastic may beovermolded onto the jaw insert 140 in a single-shot injection moldingprocess such that sealing plate 148 is overmolded to the jaw insert 140.Additionally or alternatively, the electrically insulative plastic maybe mechanically coupled to the jaw insert 140, e.g., pressed, snapped,glued, etc. Various features may be molded into the insulator 142 thatfacilitate the attachment of the sealing plate 148 to the insert 140.For example, tabs may be provided that permit a snap-fit attachment ofthe sealing plate 148, or ridges may formed that permit ultrasonicwelding of the sealing plate 148 onto the insulator 142. The sealingplate 148 may be constructed of an electrically conductive metal, andmay be stamped from a flat sheet stock.

Referring now to FIG. 10, the connection of the movable handle 122 andthe knife trigger 126 to the longitudinally movable components of theelongated shaft 116 is described. The movable handle 122 may bemanipulated to impart longitudinal motion to the outer shaft member 160,and the knife trigger 126 may be manipulated to impart longitudinalmotion to the knife rod 102. As discussed above, longitudinal motion ofthe outer shaft member 160 serves to move the end effector 114 betweenthe open configuration of FIG. 2A and the closed configuration of FIG.2B, and longitudinal motion of the knife rod 102 serves to move knifeblade 156 through knife channel 158 (FIG. 2A).

The movable handle 122 is operatively coupled to the outer shaft member160 by clevis 178 defined at an upper end of the movable handle 122. Theclevis 178 is pivotally supported on the left housing half 112 b by apivot boss 179. A second complementary pivot boss (not shown) isprovided on the right housing half 112 a to support the clevis 178. Theclevis 178 extends upwardly about opposing sides of a drive collar 184(FIG. 11) supported on the outer shaft member 160 and includes roundeddrive surfaces 197 a and 197 b thereon. Drive surface 197 a engages aproximal-facing surface of a distal spring washer 184 a and drivesurface 197 b engages a distal facing surface of a proximal rim 184 b ofthe drive collar 184 (FIG. 11). The distal spring washer 184 a engages aproximal facing surface of a distal spring stop 184 c that, in turn,engages the opposing distal locking slots 161 a, 161 b (FIG. 3A)extending through the proximal portion 166 (FIG. 3A) of the outer shaftmember 160 to couple the distal spring stop 184 c to the outer shaftmember 160. The drive surfaces 197 a, 197 b are arranged along thelongitudinal axis A-A such that pivotal motion of the movable handle 122induces corresponding longitudinal motion of the drive collar 184 (FIG.11) along the longitudinal axis A-A.

Referring now to FIG. 11, proximal longitudinal motion may be impartedto the outer shaft member 160 by pushing the proximal rim 184 b of thedrive collar 184 proximally with the movable handle 122 (FIG. 10) asindicated by arrow D4 (FIG. 11). A spring 189 is constrained between aproximal facing surface of the drive collar 184 and a proximal springstop 115. The proximal spring stop 115 engages the opposing proximallocking slots 171 a, 171 b (FIG. 3A) extending through the proximalportion 166 (FIG. 3A) of the outer shaft member 160 to couple theproximal spring stop 115 to the outer shaft member 160. Thus, theproximal spring stop 115 serves as a proximal stop against which spring189 compresses.

Distal longitudinal motion is imparted to the outer shaft member 160 bydriving the drive collar 184 distally with the movable handle 122 asindicated by arrow D3 (FIG. 10). Distal longitudinal motion of the drivecollar 184 induces a corresponding distal motion of the outer shaftmember 160 by virtue of the coupling of the drive collar 184 to opposingdistal locking slots 181 a, 181 b extending through the proximal portion166 of the outer shaft member 160 (FIG. 3A).

Proximal longitudinal motion of the outer shaft member 160 draws jawmember 132 proximally such that the cam pin 192 advances distally topivot jaw member 130 toward jaw member 132 to move the end effector 114to the closed configuration as described above with reference to FIG. 6.Once the jaw members 130 and 132 are closed, the outer shaft member 160essentially bottoms out (i.e., further proximal movement of the outershaft member 160 is prohibited since the jaw members 130, 132 contactone another). Further proximal movement of the movable handle 122 (FIG.10), however, will continue to move the drive collar 184 proximally.This continued proximal movement of the drive collar 184 furthercompresses the spring 189 to impart additional force to the outer shaftmember 160, which results in additional closure force applied to tissuegrasped between the jaw members 130, 132 (see FIG. 2B).

Referring again to FIG. 10, the trigger 126 is pivotally supported inthe housing 112 about a pivot boss 103 protruding from the trigger 126.The trigger 126 is operatively coupled to the knife rod 102 by a knifeconnection mechanism 104 such that pivotal motion of the trigger 126induces longitudinal motion of the knife rod 102. The knife connectionmechanism 104 includes upper flanges 126 a, 126 b of the trigger 126 anda knife collar 110.

Referring now to FIGS. 11, 12A, and 12B, the knife collar 110 includes apair of integrally formed pin bosses 139 a, 139 b extending fromopposing sides thereof. As shown by FIG. 12B, the knife collar 110includes an interior circular channel 113 that captures the angledproximal end 108 of the knife rod 102 to couple the knife rod 102 to theknife collar 110. Upon longitudinal motion of the outer shaft member160, the angled proximal end 108 of the knife rod 102 translateslongitudinally within the knife slot 168 (FIG. 3A) of the outer shaftmember 160 such that the longitudinal motion of outer shaft member 160is unimpeded by the angled proximal end 108 of the knife rod 102. Uponrotation of the elongated shaft 116 and end effector 114 about thelongitudinal axis A-A via the rotation knob 128 (FIG. 1), the angledproximal end 108 of the knife rod 102 freely rotates within the interiorcircular channel 113 of the knife collar 110 such that the outer andinner actuation members 160 and 180 (removed from view in FIG. 12B forclarity), and the knife rod 102 rotate within the knife collar 110 aboutthe longitudinal axis A-A. In this way, the knife collar 110 serves as astationary reference for the rotational movement of the outer shaftmember 160, the inner actuation member 180, and the knife rod 102.

Referring again to FIG. 10, the upper flanges 126 a, 126 b of thetrigger 126 include respective slots 127 a, 127 b defined therethroughthat are configured to receive the pin bosses 139 a, 139 b,respectively, of the knife collar 110 such that pivotal motion of thetrigger 126 induces longitudinal motion of the knife collar 110 and,thus, the knife rod 102 by virtue of the coupling of knife rod 102 tothe knife collar 110.

Referring now to FIGS. 11 and 12A, when the trigger 126 is moved toinduce motion of the knife collar 110 in order to translate the blade156 through the knife channel 158, the knife collar 110 translates alongthe outer shaft member 160 in the direction of arrow A5 to abut a spring119 such that spring 119 compresses against an interior portion of therotation knob 128 (FIG. 10). The spring 119 biases the knife collar 110proximally along the outer shaft member 160.

As indicated above with respect to the embodiment depicted in FIG. 10,the forceps 100 may include an enhanced switch control featureconfigured to prevent the deactivation and reactivation of the switch136 to terminate and reinitiate, respectively, the delivery ofelectrosurgical energy to the end effector 114 during operation of thetrigger 126. With reference to FIGS. 13A, 13B, 13C, and 13D, anothersuch embodiment is depicted, wherein a spring lever 135 (e.g., leafspring) extends from a proximal side of the moveable handle 122 andincludes an activation post 135 a configured to engage and depress thebutton 137 upon approximation of the moveable handle 122 with thestationary handle 120 (FIG. 13C). The spring lever 135 is biased awayfrom the surface of the moveable handle 122 from which it extends suchthat upon approximation of the moveable handle 122 with the stationaryhandle 120, the button activation post 135 a engages and depresses thebutton 137 and a spring force is applied on the button 137 by the springlever 135. Upon further approximation of the moveable handle 122 withthe stationary handle 120, the button activation post 138 engages thespring lever 135 to cause the activation post 135 a to apply additionalforce on the button 137. If the moveable handle 122 inadvertently movesdistally away from the stationary handle 120 (e.g., during operation ofthe trigger 126), as depicted by arrow M7 in FIG. 13D, the spring lever135 serves to mitigate the effects of this distal movement of themoveable handle 122 by maintaining a spring force on the button 137.This spring force maintained on the button 137 is sufficient to keep theswitch 136 activated during at least a portion of travel of the moveablehandle 122 in the distal direction (arrow M7), such that the switch 136is not deactivated and reactivated during operation of the trigger 126.As the moveable handle 122 moves farther away from the stationary handle120 to move the end effector 114 to the open configuration (FIG. 13A),the spring force maintained on the button 137 by the spring lever 135relents and, as a result, the switch 136 is deactivated.

Referring again to FIGS. 13A, 13B, 13C and 13D, a sequence of motionsmay be initiated by moving the movable handle 122 to induce motion ofthe outer shaft member 160 in order to close the jaws 130, 132, and bymoving the trigger 126 to induce motion of the knife collar 110 in orderto translate the blade 156 through the knife channel 158. Initially,both the moveable handle 122 and the knife trigger 126 are in a distalor un-actuated position as depicted in FIG. 13A. This arrangement of themoveable handle 122 and trigger 126 sustains the end effector 114 in theopen configuration (FIG. 2A) wherein the jaw members 130, 132 aresubstantially spaced from one another, and the knife blade 156 is in aretracted or proximal position with respect to the jaw members 130, 132.When both the moveable handle 122 and the knife trigger 126 are in thedistal, un-actuated position, pivotal motion of the knife trigger 126 ina proximal direction, i.e., toward the stationary handle 120, isprohibited by interference between the trigger 126 and moveable handle122. This interference prohibits advancement of the knife blade 156through the knife channel 158 when the end effector 114 is in the openconfiguration.

The movable handle 122 may be moved from the distal position of FIG. 13Ato an intermediate position depicted in FIG. 13B to move the jaw members130, 132 to the closed configuration (FIG. 2B). As the movable handle122 pivots in the direction of arrow M1 (FIG. 13B), the drive surface197 b of the movable handle 122 engages the proximal rim 184 b of thedrive collar 184. The drive collar 184 is driven proximally such thatthe spring 189 proximally biases the proximal spring stop 115 and, thus,the outer shaft member 160 is driven proximally in the direction ofarrow M2 (FIG. 13B). As discussed above with reference to FIG. 6,proximal movement of the outer shaft member 160 serves to advance thecam pin 192 distally though the cam slots 130 c, 132 c (FIG. 3A) of thejaw members 130, 132, respectively, and thus pivot jaw member 130 towardjaw member 132 (FIG. 2B). As the jaw members 130, 132 engage one anotherand no further pivotal movement of the jaw members 130, 132 may beachieved, further distal movement of the cam pin 192 and furtherproximal movement of the outer shaft member 160 are prevented.

As the movable handle 122 is moved from the distal position of FIG. 13Ato the intermediate position depicted in FIG. 13B, a tooth 122 aextending proximally from an upper portion of the moveable handle 122engages a clicker tab 120 a supported within the stationary handle 120to generate a tactile and/or audible response. This response generatedby the clicker tab 120 a corresponds to a complete grasping of tissuebetween the jaw members 130, 132 and serves to indicate to the surgeonthat further proximal actuation of the moveable handle 122 will causethe button activation post 135 a to engage the depressible button 137.As the moveable handle 122 is moved from the intermediate position ofFIG. 13B to the actuated or proximal position of FIG. 13C, the tooth 122a is positioned proximally of the clicker tab 120 a and the buttonactivation post 135 a depresses the depressible button 137, therebyactivating the switch 136 disposed within the stationary handle 120 toinitiate the delivery of electrosurgical energy to the end effector 114to generate a tissue seal or otherwise treat tissue.

As the movable handle 122 is moved from the intermediate position ofFIG. 13B to the actuated or proximal position of FIG. 13C, the pressureapplied by the jaw members 130, 132 is increased. As the movable handle122 pivots further in the direction of arrow M3 (FIG. 13C), the drivesurface 197 b presses the proximal rim 184 b of the drive collar 184further proximally against the spring 189 in the direction of arrow M4(FIG. 13C). The spring 189 is compressed against the proximal springstop 115, and a tensile force is transmitted through the outer shaftmember 160 to the jaw members 130, 132. The tensile force supplied bythe spring 189 ensures that the jaw members 130, 132 apply anappropriate pressure to effect a tissue seal.

When the movable handle 122 is in the actuated or proximal position, theknife trigger 126 may be selectively moved from the distal position ofFIG. 13C to the proximal position of FIG. 13D to advance the knife blade156 distally through knife channel 158. The knife trigger 126 may bepivoted in the direction of arrow M5 (FIG. 13D), about pivot boss 103 toadvance the flanges 126 a, 126 b of the knife trigger 126 distally inthe direction of arrow M6 such that the pin boss 139 b translates withinslot 127 b from the position shown in FIGS. 13A-13C to the positionshown in FIG. 13D. Although not explicitly shown in FIGS. 13A-13D, pinboss 139 a translates within slot 127 a in the same manner as describedabove with respect to pin boss 139 b and slot 127 b. Movement of flanges126 a, 126 b draws the knife collar 110 distally, which induces distallongitudinal motion of the knife rod 102 by virtue of the coupling ofthe knife rod 102 to the knife collar 110, as described above withreference to FIG. 12B.

While several embodiments of the disclosure have been shown in thedrawings, it is not intended that the disclosure be limited thereto, asit is intended that the disclosure be as broad in scope as the art willallow and that the specification be read likewise. Therefore, the abovedescription should not be construed as limiting, but merely as examplesof particular embodiments. Those skilled in the art will envision othermodifications within the scope and spirit of the claims appended hereto.

Although the foregoing disclosure has been described in some detail byway of illustration and example, for purposes of clarity orunderstanding, it will be obvious that certain changes and modificationsmay be practiced within the scope of the appended claims.

What is claimed is:
 1. A surgical instrument, comprising: a housing; aswitch coupled to the housing; a handle coupled to the housing andmovable between an actuated position and an unactuated position; and aswitch controller disposed on the handle, the switch controller biasedinto engagement with the switch by the handle upon movement of thehandle to the actuated position to move the switch from an unactivatedconfiguration to an activated configuration, the switch controllermaintaining the switch in the activated configuration during movement ofthe handle from the actuated position toward the unactuated position. 2.The surgical instrument according to claim 1, further comprising anelongated shaft extending from the housing, the handle configured tomove the elongated shaft longitudinally upon movement of the handlebetween the actuated and unactuated positions.
 3. The surgicalinstrument according to claim 2, further comprising first and second jawmembers disposed at a distal end portion of the elongated shaft, atleast one of the first or second jaw members configured to move relativeto the other upon longitudinal movement of the elongated shaft.
 4. Thesurgical instrument according to claim 3, wherein movement of the handlemoves the elongated shaft longitudinally relative to a stationaryactuation shaft axially disposed within the elongated shaft to move atleast one of the first or second jaw members relative to the other. 5.The surgical instrument according to claim 1, wherein the handleincludes an upper portion disposed within the housing and a lowerportion disposed exterior to the housing, the lower portion of thehandle configured to bias the switch controller into engagement with theswitch upon movement of the handle to the actuated position to move theswitch from the unactivated configuration to the activatedconfiguration.
 6. The surgical instrument according to claim 1, whereinthe handle is configured to move in a distal direction toward theunactuated position.
 7. The surgical instrument according to claim 1,wherein the handle is configured to move in a proximal direction towardthe actuated position.
 8. The surgical instrument according to claim 1,further comprising a switch activation post extending from the handleand configured to bias the switch controller into engagement with theswitch upon movement of the handle to the actuated position.
 9. Thesurgical instrument according to claim 8, wherein the switch activationpost is configured to disengage the switch controller during movement ofthe handle toward the unactuated position such that the switchcontroller moves out of biased engagement with the switch and the switchmoves from the activated configuration to the unactivated configuration.10. The surgical instrument according to claim 1, further comprising aknife blade configured to move along a longitudinal axis defined by thesurgical instrument to cut tissue.
 11. A surgical instrument,comprising: a housing; a button extending from the housing and coupledto a switch; a handle coupled to the housing and movable between anactuated position and an unactuated position, the handle including anupper portion disposed within the housing and a lower portion disposedexterior to the housing; and a switch controller disposed on the lowerportion of the handle, the switch controller biased into engagement withthe button by the lower portion of the handle upon movement of thehandle to the actuated position such that the button moves relative tothe housing to activate the switch, the switch controller causing theswitch to remain activated during movement of the handle from theactuated position toward the unactuated position.
 12. The surgicalinstrument according to claim 11, further comprising a switch activationpost extending from the lower portion of the handle and configured tobias the switch controller into engagement with the button upon movementof the handle to the actuated position.
 13. The surgical instrumentaccording to claim 12, wherein the switch activation post is configuredto disengage the switch controller during movement of the handle towardthe unactuated position such that the switch controller moves out ofbiased engagement with the button and the button moves relative to thehousing to deactivate the switch.
 14. The surgical instrument accordingto claim 11, further comprising a knife blade configured to move along alongitudinal axis defined by the surgical instrument to cut tissue. 15.The surgical instrument according to claim 11, further comprising anelongated shaft extending from the housing, the handle configured tomove the elongated shaft longitudinally upon movement of the handlebetween the actuated and unactuated positions.
 16. The surgicalinstrument according to claim 15, further comprising first and secondjaw members disposed at a distal end portion of the elongated shaft, atleast one of the first or second jaw members configured to move relativeto the other upon longitudinal movement of the elongated shaft.
 17. Thesurgical instrument according to claim 16, wherein movement of thehandle moves the elongated shaft longitudinally relative to a stationaryactuation shaft axially disposed within the elongated shaft to move atleast one of the first or second jaw members relative to the other. 18.A surgical instrument, comprising: a housing including a stationaryhandle; a switch coupled to the stationary handle; a movable handlecoupled to the housing and movable relative to the stationary handle;and a switch controller disposed on the movable handle, the switchcontroller biased into engagement with the switch by the movable handleupon approximation of the movable handle with the stationary handle toactivate the switch, the switch controller causing the switch to remainactivated during movement of the movable handle away from the stationaryhandle.
 19. The surgical instrument according to claim 18, wherein theswitch controller is configured to disengage the switch during movementof the moveable handle away from the stationary handle such that theswitch is deactivated.
 20. The surgical instrument according to claim18, wherein the switch controller is configured to be: maintained inbiased engagement with the switch by the movable handle during a firstportion of movement of the movable handle away from the stationaryhandle thereby causing the switch to remain activated; and disengagedfrom the switch during a second portion of movement of the movablehandle away from the stationary handle thereby causing the switch todeactivate.